Dual component dispensing and mixing systems for marine and military paints

ABSTRACT

A device for applying a coating comprising a multi-component cartridge comprising at least two cylindrical cartridges, each cylindrical cartridge comprising an aperture and an open filling end that is disposed opposite the aperture and that is slidingly sealed by a cartridge piston seal, a static mixing nozzle in fluid communication with each aperture, and at least one paint applicator selected from the group consisting of a roller, a brush and a spray tip, in fluid communication with the nozzle, wherein at least one flexible hose is disposed between and in fluid communication with the cartridge and the nozzle.

This application is based on U.S. Provisional Application Ser. Nos.60/533,973, filed Jan. 2, 2004, and 60/551,200, filed Mar. 8, 2004, bothpending, the entire contents of each of which are hereby incorporated byreference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to multi-component dispensing and mixing systemsfor paints and coatings. More particularly, the present inventionrelates to devices and methods for packaging, mixing, and dispensingmulti-component paints.

2. Related Art

U.S. Pat. No. 5,249,709 discloses cartridges for dispensing reactivematerials in predetermined ratios. U.S. Pat. No. 5,072,862 disclosesstatic flow mixers for use in dual cartridges. U.S. Pat. No. 4,538,920discloses a dual cartridge with a static mixer in the nozzle. U.S. Pat.No. 4,767,026 discloses dual cartridge dispensing and mixing apparatus.U.S. Pat. No. 6,135,631 discloses a static mixer and nozzle for amultiple component dispensing cartridge having at least two cylinders.U.S. Pat. No. 5,535,922 discloses a caulking gun dispenser device, whichallows one to use a multi-component cartridge dispenser in a regularcaulking gun. U.S. Pat. No. 5,875,928 discloses a two-plunger dispensinggun suitable for mixing and discharging two-component compositions. U.S.Pat. No. 6,244,740 discloses a mixer for multi-component cartridges.U.S. Pat. No. 3,166,221 discloses a plastic, double-tube dispensingcontainer. U.S. Pat. No. 3,828,980 discloses a dual cartridge dispenser.U.S. Pat. No. 6,601,782 discloses a disposable spray nozzle assembly.

Background of the Technology

The use of high solids coatings is becoming increasingly popular. In the1970's, regulatory bodies such as the Environmental Protection Agency(EPA) and the California Air Resource Board (CARB) began to scrutinizethe paint and coating industries to reduce the amount of VolatileOrganic Compounds (VOCs) released into the atmosphere. The regulatorybodies discovered that the solvents contained within paints werecontributors to air pollution. The VOCs, which are released as thesolvent evaporates from a painted surface during cure, react withnitrogen oxides to form ozone. As a result, the Clean Air Act (CAA) wasdeveloped by the EPA to regulate policies concerning the release oflarge amounts of VOCs into the atmosphere in an attempt to preventfurther damage to the environment.

Each year coating application regulations reduce the amount of allowableVOC emissions released from coatings into the atmosphere. The militaryhas begun specifying traditional solvent-based coatings and high solids,edge retentive coatings for construction and repair. These coatings werethe government's solution to service life extension and reduced lifecycle cost goals while at the same time addressing the tighteningregulations. However, with the introduction of this new coatingtechnology, new processes and handling requirements, unfamiliar topainters, were also introduced.

Multi-component, high solids paints cure by a chemical reaction thatcreates heat after mixing. With the small amount of solvent content,VOCs are greatly reduced, and the coatings provide a higher level ofperformance. These types of coatings have a much higher viscosity thantraditional solvent-based systems, making them very difficult to apply.If the coatings are manually mixed and applied, the pot life of themixture is shortened dramatically, often as short as 30 minutes and somemeasured on the order of seconds. Application environment and ratiocontrol have more effect on these coatings than traditional coatings.Pot life, viscosity and curability are all dependant at least in part ontemperature and humidity. Painters and supervisors need to continuouslymonitor these variables to produce the best product, which leads toincreased costs.

SUMMARY OF THE INVENTION

The present invention solves the above problems, and others.

One embodiment of the present invention provides a device for applying acoating, which includes:

a multi-component cartridge comprising at least two cylindricalcartridges, each cylindrical cartridge comprising an aperture and anopen filling end that is disposed opposite the aperture and that isslidingly sealed by a cartridge piston seal,

a static mixing nozzle in fluid communication with each aperture, and

at least one paint applicator selected from the group consisting of aroller, a brush and a spray tip, in fluid communication with the nozzle,

wherein at least one flexible hose is disposed between and in fluidcommunication with the cartridge and the nozzle.

Another embodiment of the invention provides a method, which includesapplying a coating to a surface with the above-described device.

Another embodiment of the invention provides a method, which includesapplying a non-skid coating to a surface with the above-describeddevice.

BRIEF DESCRIPTION OF THE FIGURES

The following description will be better understood when read inconjunction with the appended drawings. For the purpose of illustratingthe invention, there is shown in the drawings some embodiments which arepresently preferred, it being understood, however, that this inventionis not limited to the precise arrangements and instrumentalities shown.

FIG. 1 shows the general parts of a preferred embodiment of the presentinvention.

FIG. 2 shows the general parts of a preferred embodiment of the presentinvention.

FIG. 3 shows the general parts of a preferred embodiment of the presentinvention.

FIG. 4 shows the general parts of a preferred embodiment of the presentinvention.

FIG. 5 shows the general parts of a preferred embodiment of the presentinvention.

FIG. 6 shows the detail of a preferred embodiment of the presentinvention.

FIG. 7 shows the detail of a preferred embodiment of the presentinvention.

FIG. 8 shows the detail of a preferred embodiment of the presentinvention.

FIG. 9 shows the detail of a preferred embodiment of the presentinvention.

FIG. 10 shows the detail of a preferred embodiment of the presentinvention.

FIG. 11 shows a preferred embodiment of the present invention.

FIG. 12 shows a preferred embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Various other objects, features, and attendant advantages of the presentinvention will be more fully appreciated as the same becomes betterunderstood from the following detailed description of the invention,which is not intended to be limiting unless otherwise indicated.

The invention provides a multi-component industrial paint packagingsystem for use in simultaneously dispensing, mixing, brushing, rollingor spraying liquid coatings in one easy step. Preferably, the coatingsare multi-component, reactive, high-solids low-VOC paints. Morepreferably, the coatings are multi-component, reactive, high-solidslow-VOC marine, military, and industrial paints. The present inventiondesirably allows one to dispense, mix, roll, or spray two componentmarine and industrial paints in one continuous step without having topre-mix either component. It also allows dispensing of the exact amountof marine, military, and industrial paints while reducing or eliminatingthe mixer's or painter's exposure to unnecessary hazardous materials,reduces the amount of hazardous waste in application, disposal and cleanup, and reduces the amount of VOC's released into the environment. Theinvention is particularly suitable for large-scale industrialapplications because it enables significant and unexpected savings ofboth material and labor, which translates into significant cost savings.The invention eliminates the need for packaging paints in one and fivegallon cans, eliminates the need to open and premix paints, eliminatesthe need to manually pre-measure paints into exact ratios for use,significantly reduces waste and generation of excess paint associatedwith conventional methods, and provides a direct delivery method formarine and industrial paint by rolling, brushing, spraying, or powerrolling the paint onto the surface to be painted. For example, in thecourse of industrial or commercial painting on a large scale, the paintcomposition is often continually transferred from large containers tosmaller containers to avoid mixing more paint than needed and to reducethe carry burden of the individual painter.

FIG. 1 shows one preferred embodiment of the present invention. Thisembodiment includes a power roller, and the reactive paint componentsare desirably kept separate from one another and away from theatmosphere until immediately before use, when they are intimately mixedand fed to the roller for direct application. FIG. 1 shows a manualdispensing gun 2 and multi-component cartridges 1 and 1 a. Thecylindrical multi-component cartridges 1, 1 a have respective crosssectional volumes that are proportional to predetermined mixing ratios.Each cartridge preferably contains one component of a multi-componentcoating, and thus the respective reactive components (for example acoating resin and catalyst) remain separate until mixing through astatic mixer nozzle 9, and dispensed through a roller 7, which in thisembodiment is a perforated or bleed through roller.

In this embodiment, a manual dispensing gun 2 is shown. Duringoperation, piston rods 3 attached to piston plates 3 a exert a forcesufficient to push the piston plates 3 a and cartridge piston seals 4, 4a simultaneously through the multi-component cylindrical cartridges 1, 1a, which force ejects their respective contents, the reactivecomponents. The reactive paint components flow through a commondischarge nozzle 8 and into the static mixing nozzle 9, where theycontact one another. The reactive components are intimately mixed withone another as they flow through the static mixing nozzle 9.

In this embodiment, manual dispensing is initiated and controlled by atrigger system 5. The dispensing gun optionally has a handle 2 a for theuser to hold onto the dispenser while rolling the coating onto the worksurface. The mixed paint is fed from the static mixing nozzle 9 into adischarge tube 10 that feeds the mixed coating material into the roller7 for direct application to the work piece. The manual dispensing gun 2has a support arm 6 attached to it, which supports the roller attachment7.

The reactive components are ejected from their respective cartridgesinto the static mixing nozzle 9 in a ratio determined by the respectivecross-sectional areas of the cartridges 1 and 1 a. In this way, thereactive components are thoroughly mixed and in the correct proportion,and thus two sources of potential error are avoided, in contrast withconventional mixing and formulating procedures. In addition, in onepreferred embodiment, any or all of the roller 7, static mixer 9, anddischarge tube 10 are disposable, being the only components that contactthe mixed paint, so time-consuming and wasteful solvent cleaning is notnecessary. The cartridges 1 and 1 a may either be resealed for futureuse if some remains or, if none remains, they may be disposed of aswell.

Another preferred embodiment of the present invention is illustrated inFIG. 2, wherein the reactive paint components are ejected from themulti-component cartridges 1, 1 a with pneumatic or hydraulic forcethrough individual dispensing apertures 11 and into and through hoses 12to a remote roller applicator 17 that includes a power roller-typesystem for direct and continuous rolling. In this embodiment, pneumaticor hydraulic pumps 13 drive the piston rods 3, which apply continuouspressure on the cartridge piston seals 4, 4 a for a continuous supply ofpaint to the roller 7. The pneumatic pump has an air regulator 14 thatregulates the air pressure applied to the piston rods.

The twin hoses 12 attach to a coupler 15. The coupler 15 has a securingnut 16 to attach it and thus the hoses 12 to the remote rollerapplicator 17. The length of the hoses 12 may vary according to need.The remote roller applicator 17 has a trigger 18 that allows an operatorto activate the pumps 13 and dispense and apply the mixed paint ondemand and as needed. In the remote roller applicator, the reactivepaint components are mixed in the static mixer 9, and the thus-mixedpaint proceeds, still under pressure from the pumps 13, into a dischargetube 10 and to the roller 7 for direct application to the workpiece. Theremote roller applicator 17 includes a support arm 6 supports the roller7 in place during application. Preferably, the roller 7, discharge tube10, and static mixer are each independently removable and/or disposable.

One preferred embodiment is illustrated in FIG. 3, wherein pneumatic orhydraulic force to dispensing plugs for direct air assisted low pressurespray application of marine and industrial paints. The cartridges 1 and1 a are pressurized by pneumatic or hydraulic force via pumps 13, pistonrods 3 and piston plates 3 a, which apply continuous pressure on thecartridge piston seals 4, 4 a, and the reactive components are pumpedthrough hoses 12. Since each of the reactive components remains separatefrom the other in its hose there is no danger of curing and blocking thehoses 12, and thus the hoses 12 may have any length as appropriate forremote painting. The pneumatic or hydraulic pump 13 has an air regulator14 that regulates the air pressure. Hoses 12 attach to the cartridges 1,1 a by securing nuts 19 to individual dispensing apertures 11, which areillustrated in FIG. 2. The other end of the hoses 12 attach to a coupler15, which attaches in turn to a handheld remote spray applicator gun 20.The remote spray applicator gun 20 has a trigger 18 that allows theoperator to dispense the mixed paint on demand and as needed. The remotespray applicator gun 20 includes a disposable static mixer 9, and aspray tip 21 that uses regulated air for atomization of the mixed paintto spray-apply the paint to a substrate. The regulated air for ejectingand atomizing the mixed paint is supplied by a hose 22 that is attachedto the spray tip 21 and is controlled by the operator when he or shepulls the trigger 18. In an alternative embodiment of the one described,a manual dispensing gun 2 is used to pump the reactive components fromindividual apertures through hoses 12 and on to the remote sprayapplicator gun.

One preferred spray tip 21 is available from V.O. Baker, Spray TipNozzle Manifold Part No. SPRYNZZL004-VOB. An angled spray tip 21 ispreferred in view of reaching hard-to-access areas such as stiffenersnear the hull of a ship. Such spray tips have an angle between the spraydirection and the paint feed direction. Preferable angles range from 15to 90 degrees and include 15, 25, 35, 45, 55, 60, 75, 85 and 90 degrees.The spray tip 21 may attach to the nozzle by any conventional fluidconnection including Luhr-Lock, Bayonet, screw on, retaining nut, snapfit, friction fit, and the like. Friction fit is preferred.

In one embodiment, a device is provided for applying a coating,comprising, a multi-component cartridge, a static mixing nozzle in fluidcommunication with the cartridge, and at least one paint applicatorselected from the group consisting of a roller, a brush, and an angledspray tip, in fluid communication with the nozzle, wherein at least oneflexible hose is disposed between and in fluid communication with thecartridge and the nozzle.

In one embodiment of the invention, a flexible hose connects the spraytip 21 and the static mixer nozzle 9. In such an embodiment, the hose 22remains attached to the spray tip 21, but is suitably lengthened toaccommodate the length of the flexible hose between the spray tip 21 andthe static mixer nozzle 9. In this embodiment, either a manualdispensing gun 2 or a pneumatic or hydraulic dispensing gun 38 may beused, and the remote spray applicator gun 20 may also be used. Theoperator may easily hold the spray tip 21, the flexible hose, and thehose 22 in one hand for paint application, and may initiate and controlthe liquid coating flow with the remote spray applicator gun 20 in theother. In this embodiment, the spray tip 21 may or may not be angled.This desirably allows the painter nearly complete freedom of movement,in contrast with bulky and awkward conventional application techniques.Heretofore, such freedom of movement and ability to spray apply wasunknown. The flexible hose may have any length so long as the dwell timeof the mixed paint in the flexible hose does not exceed the pot life.This flexible hose may be suitably disposable.

FIG. 4 illustrates one preferred embodiment of the invention, whichincludes a manual dispensing gun 2, multi-component cartridges 1, 1 a, astatic mixer nozzle 9, and a brush applicator 23. The trigger 5 issqueezed by the operator, forcing the piston rods 3 and piston plates 3a and thus the piston cartridge seals 4 and 4 a along the length of thecartridges 1, 1 a. The reactive paint components are ejected throughcommon discharge nozzle 8 into the static mixer 9, where they arethoroughly mixed. The thus-mixed paint is fed to the brush 23, where itmay be brush-applied to the work surface. A support arm, similar to thesupport arm 6 shown in FIGS. 1 and 5, may be optionally attached to thedispensing gun 2 and the brush 23 to support the brush 23. Of course,the brush 23 and mixing nozzle 9 may be attached to a hydraulic orpneumatic pump 13 or a hand-held pneumatic or hydraulic dispensing gun38 instead of the manual dispensing gun 2. In addition, the brush 23 andmixing nozzle 9 may be combined in a separate remote assembly similar tothe remote spray applicator gun 20 connected by dual hoses 12 such asdescribed herein.

The mixed paint may be applied from the static mixing nozzle onto anouter surface of the brush bristles, or the mixed paint may be appliedto an interior portion of the brush bristles via one or more hollowpassages leading from the outlet of the static mixing nozzle through thebody of the brush 23 and into the interior part of the bristles. In thepresent context, either alternative is considered to be a fluidconnection. The latter alternative, using one or more hollow passagesthrough the brush 23, is preferred. The brush 23 and static mixingnozzle 9 are each independently removable and/or disposable.

FIG. 5 illustrates one preferred embodiment of the invention, whichincludes a manual dispensing gun 2, multi-component cartridges 1, 1 a, astatic mixer nozzle 9, a roller 7, and a roller coater 24. In thisembodiment, the mixed paint emerging from the static mixer 9 is fedthrough the roller coater 24, which applies the mixed paint onto theexterior portion of the roller 7. The operator then rolls the paint ontothe work surface with the roller 7. The roller coater 24 and roller 7are stabilized and supported by the support arm 6. Of course, the rollercoater 24 and roller 7 may be attached to a hydraulic or pneumatic pump13 or a hand-held pneumatic or hydraulic dispensing gun 38 instead ofthe manual dispensing gun 2. In addition, the roller coater 24 androller 7 and mixing nozzle 9 may be combined in a separate remoteassembly similar to the remote brush applicator 17 connected by dualhoses 12 such as described herein.

In the context of the present invention, both the power roller typeassembly using a perforated roller and the roller coater type assembly,such as described herein, are considered fluid connections. The formeralternative, using the power roller assembly, is preferred.

FIGS. 6, 7 and 8 illustrate preferred multi-component paint cartridges1, 1 a in more detail. Cartridges 1, 1 a include parallel reservoirs 26and 27 having cartridge piston seals 4 and 4 a sealing one end of each,respectively. Apertures 28 and 29 are formed in ends of reservoirs 26and 27, respectively, which oppose cartridge piston seals 4 and 4 a. Adischarge nozzle 8 is received in apertures 28 and 29, and closed by anose plug 32 removably inserted therein. A retaining nut 33 threads ontodischarge nozzle 8, holding plug 32 in position. Nut 33 is sealed by adisk 35. The reactive paint components in reservoirs 26 and 27 are mixedin specific ratios according to the respective reservoir volumes andcross sectional areas to provide a curable paint composition. Dependingupon the material employed, various ratios are required. FIG. 6illustrates a preferred multi-component paint cartridge with reservoirs26 and 27 having a 1:1 ratio. FIG. 7 illustrates a preferredmulti-component paint cartridge with reservoirs 26 and 27 having a 2:1ratio. FIG. 8 illustrates a preferred multi-component paint cartridgewith reservoirs 26 and 27 having a 4:1 ratio. One skilled in the artwill understand that reservoirs 26 and 27 can be fabricated in varioussizes to accommodate the necessary ratio of reactive components.

FIG. 9 illustrates the cross-section of a preferred static mixer 9 withcap 40. Mixing elements 41 are shown. The terms, I.D., O.D., A, and Lrepresent inner dimension of the main tube, outer dimension of the maintube, outlet inner dimension and length, respectively.

FIG. 10 illustrates the cross section of a preferred static mixer 9without cap 40. Mixing elements 41 are shown. The inlet 42 is at theupstream side relative to fluid flow, and receives the reactivecomponents. The reactive components contact and are mixed by theelements as the components traverse the length of the mixer 9, untilthey exit in the mixed paint form from the outlet 43 at the downstreamend of the static mixer 9.

In operation, removal disc 35 and nose plug 32 are removed, providing anunobstructed passage for the reactive components from reservoirs 26 and27 though apertures 28 and 29 and discharge nozzle 8. The static mixernozzle is attached to the discharge nozzle 8. The reactive paintcomponents are forced from reservoirs 26 and 27 and through apertures 28and 29 by the movement of cartridge piston seals 4 and 4 a, which aresealingly and slidably disposed within the reservoirs 26 and 27. Theejection of the components is accomplished by the use of a pneumatic orhydraulic dispensing gun 38 or a manual dispensing gun 2. FIGS. 11 and12 show other embodiments of pneumatic or hydraulic and manualdispensing guns, respectively. The dispensing gun depresses cartridgepiston seals 4 and 4 a with piston rods 3 equally to eject the correctproportions of each reactive paint component.

The piston plug 39 sometimes known as a bleeding pin or a burping pin isoptionally present in the cartridge piston seals 4, 4 a and is usefulwhen bleeding gas or air out of the reservoirs 26 and 27 when they arefilled with reactive component liquids such as paint, resin, orcatalyst, for example.

The multi-component cartridge 1 and 1 a is not particularly limiting.Suitable cartridges are described, for example, in U.S. Pat. No.5,249,709. Other suitable cartridges may be obtained commercially fromPlas-Pak Industries, Norwich Conn. The cartridges 1 and 1 a may eitherhave a side-by-side construction, or a cartridge-within-a-cartridgeconstruction. Examples of the latter are disclosed in, e.g., U.S. Pat.No. 5,310,091.

The respective cartridges 1 and 1 a may have a permanent connectionbetween them, or they may be separable, for example by one or more snapor similar connections. In one embodiment, the cartridges 1 and 1 a areconnected to one another by a snap connection near the common dischargenozzle 8. The cartridges 1 and 1 a may be made of any suitable material,such as polyethylene or nylon. Nylon is preferred. Individual reservoir26 and 27 volumes in the cartridges 1 and 1 a may each independentlyrange from 50 to 3000 ml, which range includes 50, 75, 100, 150, 250,500, 750, 1000, 1250, 1500, 1750, 2000, 2250, 2500, 2750, and 3000 ml,and any combination thereof.

The reservoirs 26 and 27 in the cartridges may each independently haveany suitable cross sectional area, in accordance with the formulationrequirements of the reactive components. The cross sectional area ratiomay range from 1:1 to 1:20, which range includes 1:1, 2, 3, 4, 5, 6, 7,8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, and 20 as appropriate.Ratios of 1:1, 1:2, 1:4 are preferred.

The present invention is particularly useful for applying liquidcoatings such as reactive two-component solvent-based coatings,edge-retention coatings, anti-corrosive coatings, high-solids coatings,low VOC coatings, Chemical Agent Resistant Coatings (C.A.R.C. paints),non-skid coatings, and the like, including but not limited to topcoatand/or primer coatings of polyurea, polyaspartic, epoxy, acrylic,silicone, polyester, polyurethane, polyamide, bisphenol A epoxy,bisphenol F epoxy, epoxy-polyamide, epoxy-polyamine, epoxy-ketamine,non-skid, aggregate-containing, aluminum oxide-containing,silica-containing, and the like.

These coatings are suitable in a variety of marine, military, off shore,petrochemical, automotive, transportation, rail, aerospace, andindustrial applications. Other suitable application examples includewithout limitation ship construction and repair of tanks, shipstructure, weapon systems, military transport vehicles, weapons,missiles, rail car repair, industrial transpiration equipments, pleasurecraft and commercial ship construction and repair, aerospace systems,off shore platforms and markings, airplane maintenance, facilities andstructures, industrial machinery and equipments, lawn and gardenequipments, rigid container and closure coatings, and food processingequipment coatings. Marine and military applications are preferred.

The coating compositions are supplied as two or more separatecomponents, usually referred to as the base and the curing agent. Whenthese components are mixed, immediately before use, a chemical reactionoccurs. These materials therefore have a limited ‘pot life’ before whichthe mixed coating must be applied. The polymerization reaction continuesafter the paint has been applied and after the solvent has evaporated toproduce a densely cross linked film which can be very hard and has goodsolvent, mechanical, and chemical resistance. There are also chemicallyresistant paints often referred to as blast primers, shop primers,temporary primers, holding primers, and the like. These types of primersare more preferably used on structural steelwork, immediately afterblast cleaning, to maintain the reactive blast cleaned surface in a rustfree condition until final painting can be undertaken.

The reactive components, for example, resin and catalyst, or base andcuring agent as more commonly referred to, may be formulated inproportions known to those of skill in the art. Preferred coatingsinclude bisphenol A epoxies and bisphenol F epoxies, with one or morepolyamide, polyamine, and ketamine being preferred as catalyst.Preferred curing agent:base ratios range from 1:1 to 1:20, with 1:1,1:2, 1:3 and 1:4 being preferred.

High-solids, low solvent or low VOC coating compositions have solidscontent approaching 100% by weight of the coating. The solids contentranges from more than 80% to 100% by weight, which includes 85, 90, 91,92, 93, 94, 95, 96, 97, 98, 99, 99.5, less than 100, and 100% by weight.The VOC or solvent content approaches zero, ranging from typically lessthan 20% by volume to zero percent, which includes 19, 17, 15, 13, 11,10, 9, 8, 7, 6, 5, 4, 3, 2, 1, 0.5, greater than zero, and zero percentby volume. Coatings having zero to 6% VOC's by volume are preferred.Coatings having 94 to 100% solids by weight are preferred.

The present invention is also suitable for high-VOC coatings, havingsolvent contents of 50 to 94% solids by weight. This range includes 50,55, 60, 62, 64, 66, 68, 70, 75, 80, 85, 90, and 94% solids by weight.These types of coatings are particularly suited for application toantennas, specialty coatings, and the like. These coatings A preferredexample of such high-VOC liquid coatings is MIL-DTL-24441.

The preferred coating compositions have short pot lives upon mixing thereactive components, ranging from 3 hours or less to 0.25 hours, whichrange includes 2.75, 2.5, 2.25, 2, 1.75, 1.5, 1.25, 1, 0.75, 0.5, and0.25 hours.

One or more than one coat may be applied. The coating compositions maycontain one or more pigments, inhibitive agents and/or pigments, andnon-inhibitive agents and/or pigments, microballoons, and the like.

One embodiment of the present invention provides a method of applying anon-skid coating composition, which includes applying to a surface anepoxy composition that contains an aggregate, such as aluminum oxide orsilica, with the paint dispensing system described herein. In thisembodiment, one of the cartridges 1 and 1 a contains a hardener, and theother contains an epoxy resin and the aggregate. The reactive hardenerand epoxy resin with the aggregate are combined and mixed in the staticmixer nozzle 9, and applied. A desirably tough non-skid surface results.

In another embodiment of the invention, a one component composition isapplied using the paint dispensing system described herein. In thisembodiment, a reactive two component paint is not used, and instead aone-component composition is contained in both cartridges. Thisembodiment provides the ability to produces a superior conventionalcoating from a convenient packaging system, and reduces waste andcleanup.

One embodiment of the invention includes a cartridge 1, 1 a thatoptionally has hermetically sealed dispensing and/or filling ends toprevent marine and industrial paints from leaking during handling,shipping and storage. The hermetic seal may be foil, plastic, or acombination thereof. Preferably, the hermetic sealing material ischemical resistant and forms a gas and liquid tight seal on either orboth of the filling ends 25 (after being filled with one reactive liquidof the multi-component coating, cartridge piston seals 4, 4 a, inserted,and degassed through piston plugs 39) and the aperture end 28, 29 of themulti-component cartridges. The hermetic seals at the aperture end ofthe cartridge may complement or replace the removal disc 35 and noseplug 32 if desired.

Static mixing nozzles 9 are not particularly limited so long as theyprogressively divide and recombine to thoroughly mix the reactivecomponents of the coating. As the reactive components traverse thelength of the static mixing nozzle 9, the number of mixing “folds”experienced by the fluid may be calculated as 2^(n), wherein n is thenumber of mixing elements present. Some examples of static mixingnozzles 9 are described, for example, in U.S. Pat. Nos. 4,850,705,4,767,026, and 4,538,920. Suitable static mixers may also be obtainedcommercially from Plas-Pak Industries, Norwich Conn.; and V.O. BakerCo., Mentor Ohio. The size of the static mixing nozzles 9 may suitablyrange from ⅛″ to 1½″ or 1 to 25 mm as appropriate, which includes ⅛″,3/16″, ¼″, 5/16″, ⅜″, 7/16″, ½″, 9/16″, ⅝″, 11/16″, ¾″, 13/16″, ⅞″,15/16″, 1″, 1¼″, 1½″ and any combination thereof. Preferably, astep-down static mixer is used, wherein the I.D. changes from ⅜″ to ¼″as one nears the outlet. Such step-down static mixing nozzles areavailable from Plas-Pak Industries, Norwich Conn. The static mixingnozzle 9 may attach to the common discharge nozzle 8 on the cartridges 1and 1 a with any suitable connection such as screw threads, Luhr-lock,lock-on retainer nut, bayonet tip, snap fit, frictional fit, and thelike.

The dispensing gun is not particularly limited so long as it is capableof applying sufficient force to the cartridge piston seals 4 and 4 a tomove the reactant components from their respective cartridges 1 and 1 athrough the static mixing nozzle 9 and on to the applicator roller 7,sprayer 21, or brush 23. The dispensing gun may be of the manual type 2,or the pneumatic or hydraulic type 38. The manual type may apply forcethrough a clutch bar, screw, ratchet or similar mechanism connected tothe squeeze trigger and handle assembly 5. One suitable manualdispensing gun is the NEWBORN 530™, manufactured by Newborn Bros. Othersuitable manual guns are described, for example, in U.S. Pat. No.5,875,928. The pneumatic type of dispensing gun is preferably regulatedand air driven. Preferred pneumatic systems include the HSS™ systems byPlas-Pak Industries, Norwich Conn. Both manual and pneumatic dispensingguns are available, for example from V.O. Baker Co., Mentor Ohio.Hydraulic dispensing systems may suitably operate at pressures on theorder of 800 psi.

The roller attachment 7 preferably includes a perforated or bleedthrough roller core and/or cover. Non-limiting examples of suitableperforated roller covers are available, for example, from Hennes-JohnsonEquipment Co., Prague Minn.; and Wagner Spray Tech Corporation,Minneapolis Minn. For the roller coater embodiment, any roller 7suitable for the paint may be used, including perforated roller coresand covers.

One preferred embodiment of the present invention provides a system thatpackages marine, military, and industrial multi-component reactiveliquid paints in cartridges for dispensing and direct rolling orspraying paints by manual, pneumatic, or hydraulic methods.

Another method of the present invention provides a method for applying ahigh-solids, low VOC marine or military paint, to a surface using amulti-component cartridge.

The current system is particularly suitable for use in dispensing andapplying multi-component coating systems, marine and military paints.Just dispensing the components in the correct proportions isinsufficient. When dispensed, the components must be mixed to activatethe curing process. As stated previously, however, manual mixing hascertain drawbacks. The present invention provides a means of storing,dispensing, mixing, and applying reactive multi-component paints at ornear point of use, conveniently, safely and with significantly reducedwaste and improved coating performance. In this manner any amount ofpaint can be prepared for use, from very small amounts to large amounts.This avoids waste and provides a system for providing just the rightamount of prepared paint for the time available for application.

The present invention desirably reduces the problems encountered withmulti-component, reactive and high-solids paints. These include theproblems of hot potting, inaccurate proportioning, mixing, and humanerror. The present invention increases the ease of coating applicationfor painters to apply coatings. In addition, because the coatingreactants remain sealed until mixed and applied, it is safer for thepainters as it reduces their exposure to often toxic reactants, such ascuring catalysts, isocyanates, and the like. In addition, the presentinvention results in a more manageable process on an industrial scale,it drastically reduces paint can change out time, waste due to expiredpot life and spillage, and clean-up solvent. The present invention isparticularly suitable for marine and military paint multi-componentpaints.

In accordance with the present invention, preloaded disposable paintcartridges with disposable static mixers keep the base and hardenerseparate from one another as long as possible and allow dispensing ofpaint on demand. A preloaded disposable paint cartridge with disposablestatic mixer is used to mix the multi-component systems as close to thecartridge as possible. The use of preloaded disposable paint cartridgeswith disposable static mixers eliminates pot life problems and viscosityproblems that result in waste and application difficulties.

Preloaded disposable military and marine paint cartridges withdisposable static mixers reduce the problems encountered with viscosityand pot life by keeping the two components separate as long as possible.Keeping the reactive components of multi-component coatings separateeliminates the risk of the coatings curing before use. Components aremixed at the work site when needed. This not only reduces the amountmixed and waste generated, it improves product integrity by maintainingexact ratios, thereby allowing the end user to achieve maximum servicelife expectancy.

Military and marine coatings are much more sensitive than traditionalsolvent based epoxies and coatings. In the present application, marineand military paints are especially formulated to be used in a saltwatermarine environment and/or are specified by the U.S. military, such asthe U.S. Army, Navy, Marine Corps, Air Force, Military Sealift Command,and/or Coast Guard. These coatings must be mixed properly and thoroughlyaccording to manufacturers specifications in order to cure. High solidscoatings, and particularly those for marine and military applications,have specific mix ratios with very tight tolerances, generally plus orminus 3%. There are many different factors that affect whether a coatingwill be on or off ratio. In accordance with the present invention,preloaded disposable military and marine paint cartridges withdisposable static mixers assures the mix ratios are maintained whendispensing. In accordance with one embodiment of the present invention,these dispensing systems are combined with a paint roller or brushingapparatus and method. In accordance with another embodiment of thepresent invention, a multi-component cartridge preloaded with one ormore reactive components of a high solids, low VOC marine and militarypaint.

The entire contents of each of the references, patents, and patentapplications cited herein is hereby incorporated by reference, the sameas if set forth at length.

Obviously, numerous modifications and variations of the presentinvention are possible in light of the above teachings. It is thereforeunderstood that within the scope of the appended claims, the inventionmay be practiced otherwise than as specifically recited herein.

1. A device for applying a coating, comprising: a multi-componentcartridge comprising at least two cylindrical cartridges, eachcylindrical cartridge comprising an aperture and an open filling endthat is disposed opposite the aperture and that is slidingly sealed by acartridge piston seal, a static mixing nozzle in fluid communicationwith the each aperture, and at least one paint applicator selected fromthe group consisting of a roller, a brush, and a spray tip, in fluidcommunication with the nozzle, wherein at least one flexible hose isdisposed between and in fluid communication with the cartridge and thenozzle.
 2. The device of claim 1, wherein the paint applicator is aroller.
 3. The device of claim 1, wherein the paint applicator is aroller, and the roller is a perforated roller.
 4. The device of claim 1,wherein the paint applicator is a roller, and wherein the roller is aperforated roller having an interior in fluid communication with thenozzle.
 5. The device of claim 1, wherein the paint applicator is aroller, the device further comprises a roller coater disposed betweenthe roller and the nozzle, and the roller coater is in fluidcommunication with both the nozzle and an exterior surface of theroller.
 6. The device of claim 1, wherein the paint applicator is abrush.
 7. The device of claim 1, wherein the paint applicator is a brushwith bristles, and wherein the brush further comprises a hollow passagedisposed between and in fluid communication with both an interior partof the bristles and the nozzle.
 8. The device of claim 1, wherein thepaint applicator is a brush with bristles, and wherein an exterior partof the bristles is in fluid communication with the nozzle.
 9. The deviceof claim 1, wherein the applicator is an angled spray tip having aninlet with an axis defined by a fluid communication direction thereinto,and having a spray outlet with an axis defined by a spray direction,wherein an angle between the inlet and outlet is 15 to 90 degrees. 10.The device of claim 1, wherein each aperture is in fluid communicationwith a common discharge nozzle, the discharge nozzle being in fluidcommunication with the static mixer nozzle.
 11. The device of claim 1,further comprising a manual, pneumatic, or hydraulic dispensing gun, incontact with the cartridge.
 12. A method, comprising applying a non-skidcoating to a surface with the device of claim
 1. 13. The method of claim12, wherein the non-skid coating comprises an epoxy coating containingat least one aggregate material selected from the group consisting ofaluminum oxide, silica, and a mixture thereof.
 14. The method of claim12, wherein the non-skid coating comprises an bisphenol F epoxy,bisphenol A epoxy, polyurethane, or a mixture thereof.
 15. A method,comprising applying paint to a surface with the device of claim
 1. 16.The method of claim 15, wherein the paint contains at least one selectedfrom the group consisting of polyurea, polyaspartic, epoxy, acrylic,silicone, polyester, polyurethane, polyamide, bisphenol A epoxy,bisphenol F epoxy, epoxy-polyamide, epoxy-polyamine, epoxy-ketamine,C.A.R.C. paint, non-skid aggregate, aluminum oxide, silica, and acombination thereof.
 17. The method of claim 15, wherein the paintcomprises bisphenol F epoxy, bisphenol A epoxy, polyurethane, or amixture thereof.